Method of and apparatus for use in preparing weaving warps



Sept-3, 1946. Y J. BOLTON ,9 8 METHOD OF AND AP-PARATUS FOR USE INPREPARING WEAVING' WARPS Filed Aug. 22, i944 Patented Sept. 3, 1946UNITED STATE METHOD OF AND APPARATUS" FOR USE IN PREPARING WEAVING WARPSJames Bolton, New Bedford, Mass. Application August 22, 1944, Serial No.550,540

This invention pertains to the manufacture of textile fabrics,specifically to a method of making fabrics, especially useful in thepreparation of sheer fabrics from rayon or similar yarns, and to a novelmethod of preparing warps for use in weaving looms and to a novel meansfor use inv the practice of said method.

A completed weaving warp mounted on the loom beam often comprises manythousands of yarn ends, each of a length which may exceed 20,000 yards,and the preparation of this yarn mass has heretofore customarilyinvolved a substantial number of handlings of each individual yarnsubsequent to spinning, each of these several handlings being apotential source of knot formation so that in the completed warp a greatmany knots customarily occur. Such knotsappear in the woven fabric,particularly if the fabric is a thin or sheer material such asmarquisette, as distinct and readily visible imperfections, thusdetracting from the appearance and value of the material. Moreover, suchprior methods, involving many handlings of the individual yarns, consumetime, require much space for the necessary equipment, and thussubstantially add to the cost of production.

Such prior methods of warp preparation, for instance, may involvewinding the yarn from the spinning bobbin onto a twister bobbin, thenwinding the yarn onto a "spooler bobbin to form a yarn mass, forinstance 4 x 5" and of a yarn length, for instance of 24,000 yards; thenplacing these spooler bobbins in a creel andwinding, for instance, 500ends onto a section beam; and then assembling, for instance, four ofthese section beams and winding the yarns from them onto the loom beam.Another somewhat less complex prior method involves placing the twisterbobbins in a creel; winding, for instance, 500 ends directly from thesebobbins onto a warper reel or mill, these 500 ends passing through, forinstance, a reed, then. moving the reed axially of the reel and windingon another of the 500 ends, etc., until the reel holds the entire numberof ends desired, and then drawing the yarns from the reel, and windingthem directly onto the loom beam, but it is easy to see that in each ofthese prior methods, the yarn is handled a substantial number of timesbetween spinning and warp.

In windinga beam directly from yarn packages mounted in a creel, theyarns from the. several packages are passed through a comb whichdisposes them in a sheet. The comb disposes the yarns in very closelyspaced relation in a sheet 11 Claims. (Cl. 2832) I whose widthapproximates the width of the desired warp.

However, a common difficulty encountered in the, winding of yarns onto asection or loom beam, in particular twisted yarns, results from thetendency of the yarns constituting the sheet to roll and thereby tobecome enmeshed with or to adhere to adjacent yarns. This tendency toroll or move transversely of the direction of yarn travel maybe partlydue to the effects of static electricity, and partly to the stressesimposed up'on the constituent fibers during spinning and twisting, butwhatever its cause, it is a common source of snarling and breaking.Thus, if it be attempted to employ a second comb, very closely adjacentto the beam, in order accurately to deliver the yarns to the beam inproper relation, many of the laterally displaced yarns, enmeshed withadjacent yarns and traveling at high speed, will be broken when theyengage the second comb. When it is practical (as for instance in a loom,where the linear speed of the warps isvery low) toemploy separator rodsand combs, or their equivalent, at frequent intervals along the lengthof the travelling yarns, this tendency to roll may thereby be controlledalthough the space necessary for such dividers or similar equipment andthe expenseinvolved in its use is often prohibitive, but in a high speedwarper this method of control can not be employed.

The present invention has for its principal object the provision of animproved method of preparing a warp whereby the entire number of ends'requisiteto constitute the completed warp may be wound directly frombobbins (for example twister bobbins) onto the loom beam, therebyeliminating many of the steps previously considered necessary andincidentally so diminishing the number of.knots in the completed Warpthat the woven fabric is far freer from defects (knots) than it hasheretofore been possible to produce by any practical method. A furtherobject is to provide an improved method of controlling yarns duringwinding even at high speeds, for instance while winding parallel yarnsonto a loom beam, so as substantially to prevent the yarns from rollingand thereby becoming intermeshed or adherent to one another and thus topreventsnarling and breakage and also, if desir-ed, concomitantly totension the yarns.

A further objectis to provide improved appa- 3 that the method iscapable of performance by specifically different means.

Other and further objects and advantages of the invention will bepointed out in the following more detailed description and by referenceto the accompanying drawing wherein Fig. l is a diagrammatic plan viewof apparatus useful in the practice of the present invention;

Fig. 2 is a side elevation of the apparatus shown in Fi 1;

Fig. 3 is a fragmentary perspective View to larger scale and in part invertical section show me one of the yarn-positioning and tensioningelements;

Fig. 4 is a fragmentary longitudinal section through one of theyam-positioning elements; and r Fig. 5 is a fragmentary front elevationof a yarn-separating comb forming a part of the apparatus.

Referring to the drawing the numeral I designates a suitable support,for example a creel designed to support yarn packages, in number atleast as great as the number of ends in the desiredwarp. Preferably thecreel is so arranged that these yarn packages may turn, thus permittingthe yarn to be unwound without removing or imparting twist to theunwinding yarn. Individual tensions may be provided for these unwindingpackages, if desired, as is customary in creels in which the yarnpackages rotate and each of these yarn packages 2 may, for example, be atwister bobbin containing a length of yarn, for instance 24,000 yards,more than sufficient to form one end of the desired completed warp.

The warper 3 may in general be of a more or less conventional typedesigned removably to support a loom beam having spaced heads 4 and 5,the beam being fixed to a shaft 6 whose opposite ends are supported inbearing brackets l and 8, preferably relatively adjustable toaccommodate beams of different lengths. The shaft 6 is provided with agear 9 which mesheswith a pinion driven by a shaft H] which receives itsmotion, through an endless belt H, from a motor-driven variable speeddevice [2, for example a mechanism such as is commonly known as a Reevesdrive, the speed ratio of this drive being variable by the actuation ofa hand wheel l3 or equivalent device. Thus by manipulation by the handwheel l3 the angular velocity of the warp beam shaft 6 may be varied.

From the packages 2 the yarns Y are led through suitable guide eyes to acollecting comb l4, usually of a length substantially greater than theWidth of the desired warp and with this comb M (which is an end-and-endlease comb enabling the operator to put in a full end-and-end lease atthe end of each warp which is made) lease rods l5 and It may beassociated, if desired. After passing the collecting comb l4 and leaserods l5 and I6, the yarns pass through a yarnpositioning or guide combI7. This comb I! (Fig. 5) has dents D in each of which one and sometimestwo yarns Y may be placed and is of such length that the endmost yarnsof the warp sheet are spaced apart a distance substantially exactly thewidth of the desired warp, the endmost dents of the comb being disposedsubstantially in the parallel planes of the respective inner surfaces ofthe heads 4 and 5 of the warp beam. Thus after passing the comb I! theyarns form a sheet S in which the yarns are all side by side and substantially parallel. Preferably after passing the comb I! the yarnsextend partially around smooth surfaced, accurately cylindrical rolls i8and I9 whose axes are parallel to the length of the comb I! and to theaxis of the warp beam. In order to control the yarns after passing theroll I 9 and before they reach the winding-on point of the warp mass onthe loom beam, there is provided a controller device 20 which, as hereshown, more or less resembles the usual Warper mill or reel.

Thus this controller comprises a shaft 2i mounted to turn in suitablebearings and with its axis paryarn is drawn over the outer surface ofthe element and is subjected to tension, the yarn tends to embed itselfin the substance of the positioning element as shown for example in Fig.4, so that lateral movement or rolling of the yarn is thereby prevented.The controlling element or reel 29 is not driven except by thefrictional drag of the yarns in contact with the elements 25, but ispreferably furnished with a brake drum 26 which is engaged by a flexiblebrake band fixed at one end at 28 and having a weight 29 at its oppositeend. By varying the mass of the part 29 the braking effect may bevaried, thereby to determine the density of the Warp mass on the beam orto accommodate yarns of different materials.

In the operation of the apparatus and assuming that the yarns Y havebeen threaded through the combs M and I1 and passed about the reel 20and connected to the barrel of the drum, the operator, in starting thewarp beam, will first so manipulate the hand wheel I3 as to impart a lowangular velocity to the beam, thereby slowly starting the beam intooperation so as to avoid overtensioning and breaking of any of theyarns. However, as soon as the beam has picked up speed, the operatorwill manipulate the wheel [3 so as to turn the warp beam shaft 5 at itsmaximum velocity as determined by the characteristic of the yarns to bewound. Thereafter as the diameter of the winding mass on the beamincreases the operator will, from time to time, so manipulate the wheell3 as gradually to reduce the angular velocity of the warp beam therebyto maintain a substantially uniform but high linear speed of the yarnduring the entire winding operation, after first starting up. It will beunderstood, however, that if at any time during the warping operation itbe necessary to stop the machine, the operator will again start up atslow speed before resuming the previous high and substantially uniformwinding speed.

The entire tension placed on the winding yarns is produced by the pulldeveloped b the power driven loom beam and by the retarding action ofthe yarn-engaging elements 25 which resist the forward movement of theyarns to an extent depending upon the load placed on the brake band 21.

It is to be noted that from the time the yarns Y engage the first of theseries ofyarn-controlling elements 25 until the yarns are about to windonto the warp beam they are kept under constant restraint againstsidewise movement or rolling so that the parallel relation imparted bythe comb I1 is substantially maintained until they are incorporated inthe winding mass on the beam. Thus even though the linear winding speedof the yarns be veryhigh there is no danger of their becoming enmeshedwith each other so that upon the subsequent unwinding of the beam theywill be snarled and broken. On the other hand, by the employment of thissimple controlling device 20, the accurate parallel relation of theyarns is insured without resort to complicated, expensive andspace-using separator devices such as have heretofore been proposed andmost of which are inapplicable to high speed operations.

Preferably, in accordance with this improved method and as abovesuggested, each of the yarn packages 2contains a length of yarnsubstantially greater than that required to form one end of thecompleted warp. Since these yarns from the packages 2 are thus delivereddirectly to the loom beam, and since although this apparatus winds thewarps at very high speed, very little breakage results, the number ofknots in the completed warp is thus very much smaller, for example 50%less than is commonwhen a warp is prepared in accordance with usualprior methods. After the warp has been completed, the yarn remaining onthe packages 2 is then preferably wound directly onto the weaving bobbinand is used with the warp from the beam in weaving the desired cloth.Thu the filling also contains less knots than usual and the resultingfabric, both in warp and weft has much fewer knots than customary. Bythus using the remainder of the yarn on packages 2 inwinding not greatlyexceed the longest of the desired warps, since this remainin yarn on thepackage 2' is not wasted.

.As a specific example of the practice of this novel method, nineteenthousand yards of rayon yarn of 70'denier, having twenty turns of twistper inch, are wound on each of the requiste number of twister bobbinsand used in winding warps, each of a length of three thousand yards.Each twister bobbin thus provides enough yarn to form one warp end forsix full loom beams, with enough yarn remaining to wind a full fillingbobbin. In order to avoiod the necessity for sizing the yarns, inaccordance with the present invention they are preferably twisted toprovide the requisite strength, acrepe or voil twist being used.

In Winding, and after first starting the beam into motion, a uniformlinear yarn speed of, for example, sixty yards per minute is safeandpractical, and may be maintained throughout the winding operation,although if preferred, as the yarn masses on the bobbins become verysmall, the speed of win-ding may be reduced for instance to fifty yardsper minute to avoid undue bobbin speed.

Since beams of different lengths may readily be substituted one foranother merely by changing the relation between the beam supports 1 and8, and since the positioning elements 25, traveling with the yarns fromthe comb ll toward the beam, exactly maintain the width of the warpsheet as determined by the comb ll, it is possible to wind any width ofloom beam in this apparatus simply by Varying the effective length ofthe comb ll.

While one desirable embodiment of the invention is herein disclosed byway of example, it is to be understood that other and equivalent meansand method steps may be used within the scope of l the invention asdefined by the appended claims. i

I claim:

1. In apparatus for winding a Warp on a loom beam-in combination, meansfor supporting yarn masses in number at least equal to the number ofends in the desired warp, a comb operative to. dispose the yarns in sideby side relation, the length of the comb being substantially equal tothe width of the desired warp, a loom beam and means for rotating thebeam, the axis of the beam being parallel to the length of the comb, anda series of spaced yarn-positionin elements which move with the yarns asthe latter appreach the winding mass on the beam, said positioningelements being constructed and arranged to prevent the yarn fromrolling.

2. In apparatus for winding 3, warp on a loom beam in combination, meansfor supporting and for turning a loom beam and a loom beam mounted insaid supporting means, means for supporting spaced yarn packages innumber at least equal tothe number of ends in the desired Warp, a combhaving dents each designed to receive one or more warp ends and of suchlength as to dispose said ends in a sheet of a width of the desiredwarp, and an endless series of yarnengaging elements interposed betweenthe comb and the beam and which are operative to deliver the yarnsdirectly to the beam, each' of said elements being of soft, resilientmaterial in which each yarn embeds itself, and means for moving saidelements in the direction of yarn travel.

3. In the apparatus for winding a warp on a loom beam in combination, acreel having provision for holding yarn masses in number at least equalto the number of ends in the desired Warp, a comb having dents eachdesigned to receive one or more warp ends and of such length as todispose said ends in a sheet of the width 0f the de-- sired warp, and areel interposed between the comb and the beam, theatres of the reel andbeam being substantially parallel to the length of the comb, the reelhaving spaced peripherally arranged yarn-engaging elements which deliverthe yarn directly to the beam and which are so constructed and arrangedas to prevent the yarns from rolling as they move toward the windingwarp mass on the beam.

4. In apparatus for winding a warp on a loom beam in combination, meansfor supporting and for turning a loom beam and a loom beam mounted insaid supporting means, means for rotatably supporting yarn packages innumber at least equal to the number of ends in the desired warp, a creelhaving provision for rotatably supporting yarn packages in number atleast equal to the number of ends in the desired warp, a combconstructed and arranged to dispos the yarns in parallel relation, thelength of the comb substantially equalling the width of the desiredwarp, a rotatable reel of a diameter substantially larger than that 'ofthe beam and which turns on an axis parallel to that of the beam, thereel being so arranged that the yarn on its way from the comb to thebeam embraces a portion of the periphery of the rim, the reel havingperipherally spaced yarn-engaging elements each of resiliently yieldablematerial and from which the yarns are delivered directly to the beam,and means opposing free rotation of the reel thereby to tension theyarns.

5. Apparatus for use in p p n weavin warps comprising a support forbobbins in number at least as great as the number of warp ends, a loombeam and means for rotating it at a variable angular velocity such thatthe linear speed of the winding yarn is substantially constantthroughout the winding operation, a comb-guide for disposing the severalyarns in substantially parallel relation, a rotary support turning aboutan axis parallel to that of the beam, said support carrying a pluralityof peripherally yarn-engaging spaced friction elements from which theyarns are delivered directly to the beam, means operative to cause theparallel yarns partially to wrap about said rotary support on their wayfrom th comb-guide to the beam and to engage said friction elements, andmeans to restrain the free rotation of said rotary support thereby totension the yarn.

6. Apparatus for use in preparing weaving warps comprising a support forbobbins in number at least as great as the number of warp ends, a loombeam and means for rotating it, a combguide for disposing the severalyarns in substantially parallel relation, a reel arranged to turn aboutan axis parallel to that of the beam, said reel having a plurality ofperipherally spaced transverse bars each provided with a friction padfrom which the yarns contact and from which the yarns are delivereddirectly to the beam, guide means constraining the yarn on its way fromthe comb-guide to the beam partially to wrap about the reel and therebyconcomitantly to engage a plurality of said pads, and a brake cooperablewith the reel to retard rotation thereof whereby the linear speed ofsaid pads is less than that of the traveling yarn.

7. In apparatus for winding a warp on a loom beam in combination, meansfor supporting and turning a loom beam, a loom beam mounted in saidsupporting beams, a creel having provision for rctatably supportin yarnpackages in numa ber at least equal to the number of ends in the desiredwarp, a comb having'dents for the reception of the warp ends and of alength substantially equalling the width of the desired warp, the warpbeam having its axis parallel to the length of the comb, and a series ofspaced movable pads of yielding resilient material, each of a length atleast equal to that of the comb, and which are parallel to the latterand which engage each of the several yarns as they are moving from thecomb toward the beam and from which the yarns are delivered directly tothe beam and into which each individual yarn embeds itself, and meansfor moving said pads toward the beam while keeping them parallel to thecomb thereby to constrain each individualyarn to move in a path locatedin a plane perpendicular to the axis of the beam.

8. That method of preparing a weaving warp which comprises as stepsproviding yarn masses in number equalling the desired number of yarnends in the completed warp and each consisting of a single yarn whoselength at least equals the length of the desired warp, simultaneouslydrawing off the yarns from the several yarn masses and passing thembetween separator elements thereby to dispose them side by side to forma sheet of a width substantially equal to that of the desired warp,winding the several yarns directly onto a loom beam while engaging eachindividual yarn with a soft, resilient element in which the yarn ispartially embedded thereby to keep it from rolling and from which theyarn passes directly to the beam, and bodily moving said element withthe yarn as the latter approaches the winding yarn mass.

9. That method of preparing a weaving warp which comprises as stepsproviding yarn masses in number equalling the desired number of yarnends in the completed warp and each consisting of a single yarn whoselength at least equals the length of the desired warp, simultaneouslydrawing off the yarns from the several yarn masses and passing thembetween separator elements thereby to dispose them side by side to forma sheet of a width substantially equalling the width of the desiredwarp, winding the several yarns under substantially equal tension upon aloom beam, and partially embedding each individual yarn, during itstravel from the separator elements to the winding yarn mass, in a seriesof spaced resiliently yieldable parts which travel in succession withthe yarns toward the beam, thereby to prevent rolling of the yarns.

10. That method of preparing a weaving warp which comprises as stepsproviding yarn masses in number equalling the desired number of yarnends in the completed warp and each consisting of a single yarn whoselength at least equals the length of the desired warp, simultaneouslydrawing off the yarns from the several yarn masses and passing thembetween separator elements thereby to dispose them side by side to forma sheet of a Width substantially equal to that of the desired warp,winding the several yarns directly onto a loom beam while preventingthem from rolling during their passage from the separator elements tothe winding warp mass by embedding each yarn individually in a series ofspaced yieldable positioning elements which move with the yarns towardthe winding warp mass, the angular velocity of the m beam beinggradually accelerated, when starting empty, up to its maximum value andthen being gradually diminished as the winding mass increases indiameter.

11. In apparatus for winding a warp on a loom beam in combination, meansfor supporting and for turning a loom beam and a loom beam mounted insaid supporting means, means for supporting yarn masses in number atleast equal to the number of ends in the desired warp, a comb operativeto dispose the yarns in parallel relation, the length of the combsubstantially equalling the width of the desired warp, a rotatable reelinterposed between the comb and beam and turning on an axis parallel tothat of the beam, said reel having peripherally spaced yarnengagingelements from which the yarns are delivered directly to the beam, eachof said elements having the characteristic resilience of sponge rubberso that the moving yarns embed themselves in said elements.

JAMES BOLTON.

